Wall panel for building structure comprising a fibreglass outer shell and a frame assembly positioned within the shell

ABSTRACT

A WALL PANEL AND METHOD OF MAKING SAME HAVING A DESIRED SHAPE FIBERGLASS BASE MEMBER AND A PLURALITY OF METALLIC SUPPORT MEMBERS AFFIXED THERETO FOR WELDING THE WALL PANEL TO A BUILDING STRUCTURE. THE METALLIC SUPPORT MEMBERS ARE OF A HAT OR ANGLE SHAPE AND ARE FIBERGLASSED TO THE BASE MEMBER. AN ADHESIVE TAPE IS PLACED BETWEEN THE SUPPORT MEMBERS AND THE BASE MEMBER TO INSULATE THE BASE MEMBER FROM CHANGES IN THE WEATHER CONDITIONS AND FROM HEAT BEING APPLIED TO THE SUPPORT MEMBER. THE EXTERIOR OF THE FIBERGLASS BASE MEMBER IS SANDBLASTED AND COATED WITH AN EPOXY COMPOUND FOR PROVIDING ANY DESIRED APPEARANCE.

Aug. 10, 1971 CLARK 3,598,685

WALL PANEL FOR BUILDING STRUCTURE COMPRISING A FIBREGLASS UTER SHELL ANDA FRAME ASSEMBLY POSITIONED WITHIN THE SHELL Filed Feb. 19, 1969 3Sheets-Sheet 1 lNl/ENT OQl Jam 5 CMA K BKJM @W/ Aug. 10, 1971 J. E.CLARK WAN. PANI'HJ FOR BUILDING STRUCTURE COMPRISING A FIBREGLASS OU'IHRSHELL AND A FRAME ASSEMBLY POSI'IIONED Filed Feb. .1), 1969 WITHIN THESHELL 3 Sheets-Shoot a INVENTOR Joy/v 5 (244% ATTORNEYS Aug. 10, 1971WALL PANEL FOR BUILDING STRUCTURE COMPRISING A FIBREGLASS OUTER SHELLAND A FRAME ASSEMBLY POSITIONED Filed Feb. 19, 1969 J. E- CLARK WITHINTHE SHELL 5 Sheets-Sheet 5 wka/vroe Ja /v [C (24w XImQA/Em United StatesPatent Ofice 3,598,686 WALL PANEL FOR BUILDING STRUCTURE COM- PRISING AFIBREGLASS OUTER SHELL AND A FRAME ASSEMBLY POSITIONED WITHIN THE SHELLJohn E. Clark, 572 Collier Road NW., Atlanta, Ga. 30318 Filed Feb. 19,1969, Ser. No. 800,431 Int. Cl. B32]: 1/04, 3/12 US. Cl. 16141 8 ClaimsABSTRACT OF THE DISCLOSURE -A wall panel and method of making samehaving a desired shape fiberglass base member and a plurality ofmetallic support members aflixed thereto for welding the wall panel to abuilding structure. The metallic support members are of a hat or angleshape and are fiberglassed to the base member. An adhesive tape isplaced between the support members and the base member to insulate thebase member from changes in the weather conditions and from heat beingapplied to the support member. The exterior of the fiberglass basemember is sandblasted and coated with an epoxy compound for providingany desired appearance.

BACKGROUND OF THE INVENTION This invention relates generally to wallpanels and more particularly to a shaped fiberglass wall panel for usein building construction.

In the past, wall panels for use in construction buildings weregenerally made of metal or concrete. Such wall panels were found to beboth expensive and to lack the flexibility needed for readily forming anumber of different shaped panels. Moreover, concrete wall panels werefound to be extremely heavy thereby requiring heavy equipment to installsame.

Because of the difficulties encountered with metal wall panels, othershave tried to use fiberglass. While somewhat satisfactory, one of theproblems immediately encountered was that the fiberglass discolored inthe welding process due to temperature changes. Another problem was thatthe supporting members had to be attached to the fiberglass panels sothat the same could be welded to the building structure. However,difficulties were immediately encountered in attaching the supportmembers to the fiberglass panel. Moreover, a need existed for a wallpanel that could take on a plurality of different asthetic appearancesas desired.

SUMMARY OF THE INVENTION Accordingly, one object of the presentinvention is the provision of a new and improved wall panel.

Another object of the present invention is the provision of a new andimproved fiberglass wall panel which is capable of taking on a number ofdifferent shapes.

A further object of this invention is the provision of a new andimproved fiberglass wall panel which is both inexpensive and easy toconstruct.

Still another object of the present invention is the provision of a newand improved fiberglass wall panel which uses a panel member with aplurality of readily attachable and different shaped support members.

Yet a further object of the invention is to provide a new and improvedfiberglass wall panel which is capable of withstanding greater changesin temperature conditions than heretofore existed.

One other object of the instant invention is the provision of a new andimproved fiberglass wall panel which 3,598,686 Patented Aug. 10, 1971 iscapable of taking on any desired exterior appearance and which is lightin weight.

Briefly, in accordance with this invention the foregoing and otherobjects are attained by fiberglassing metallic support members to afiberglass base member with insulation provided therebetween in such afashion that both a strong connection and insensitivity due totemperature is readily realized.

BRIEF DESCRIPTION OF THE DRAWINGS A more complete appreciation of theinvention will be readily apparent as the same becomes better understoodby reference to the following detailed description when considered inconnection with the accompanying drawings wherein:

FIG. 1 is an exploded perspective view of one embodiment of theinvention;

FIG. 2 is a front elevational view of a modification of the embodimentshown in FIG. 1;

FIG. 3 is partial cross-sectional view showing the connection of ahat-shaped channel used in the invention;

FIG. 4 is a cross-sectional view taken along line 44 in FIG. 2; and

FIG. 5 is a cross-sectional view of a modification of the inventiontaken along line 55 as in FIG. 2.

These figures and the following detailed description of the inventiondisclose specific embodiments thereof, however, the inventive concept isnot limited thereto since it may be embodied in other specificembodiments.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS Referring now to thedrawings wherein like reference numerals designate corresponding partsthroughout the several views, it will be seen that the wall panelcomprises generally a fiberglass shell 10 which is carried by a frameassembly 11. The frame assembly 11 is fiberglassed into the shell '10and the frame assembly 11 is welded to the supporting structure of thebuilding (not shown). The wall panel may be made with various openingstherein depending on what is to be inserted into the wall panel after itis placed on the supporting structure. The particular Wall panel shownin the figures is designed for use with a window, however, it is to beunderstood that spaces for door, as well as other openings, may beprovided therein or the panel may be left blank. It is furtherunderstood that the wall panel as illustrated in the figures has arectangular shape, however, the shape thereof is not limited to theparticular shape shown but may be formed into any desired configuration.

The wall panel shown in FIG. 1 illustrates one embodiment of afiberglass shell 10 which may be part of the invention. In thisparticular embodiment of the fiberglass shell 10, it will be seen thatthe shell 10 is of a molded fiberglass construction which includes afront panel 12, a pair of opposed side panels 14 integrally molded withthe front panel 12 and connected thereto through a bevel portion 15. Theshell 10 also includes a top panel 16 and an opposed bottom panel 18which are also integral with the front panel 12 through the bevelportion '15 and integral with the side panels 14 at their ends. A windowopening 19 is provided through the shell 10 and includes a plurality ofsub-panels '20 which extend from the inside surface of the front panel12 as do the side panels 14 and the top and bottom panels '16 and 1 8.The sub-panels 20 are integrally formed with the front panel 12 througha lip portion 21 which extends forward to the front surface of the frontpanel 12 to define the window opening. A sealing flange 22 is providedalong the rearmost edge of one of the side panels 14 and the top panel16 generally parallel to the front panel 12 and extending outward of 3the shell 10. The shell is usually molded in a conventional fiberglassmold in the desired configuration and, removed therefrom when dry sothat the shell 10 is ready for receipt of the frame assembly 11 therein.

The only difference of the embodiments of the invention shown in FIG. 1,and the embodiment of the invention shown in FIG. 2, with regard to theshell 10 is that the opening 19 in the shell 10 in FIG. 2, is wider thanthat shown in FIG. 1. The shell 10 shown in FIG. 5, is the same as thatshown in FIG. 1.

One embodiment of the frame assembly, designated 11, is shown in FIG. 1,a second embodiment, designated 111, is shown in FIGS. 2 and 4, and athird embodiment designated 211, is shown in FIG. 5. The differencestherebetween will be explained more fully hereinafter.

Referring particularly to FIG. 1, the frame assembly 11 comprises a pairof opposed side reinforcing angles of L-shape configuration, each havinga shell mounting flange 26 and an exposed panel mounting flange 28. Theupper ends of the angles 25 are joined by an L-shaped top reinforcingangle 29 having a shell mounting flange 30 corresponding to flange 26and an exposed panel mounting flange 31 corresponding to flange 28. Thelower ends of the angles 25 are joined by an L-shaped bottom reinforcingangle 32 having a shell mounting flange 34 corresponding to flanges 26and 30 and an exposed panel mounting flange 35 corresponding to flanges28 and 31. The angles 25, 29, and 32 are assembled 'with the flanges 26,30, and 34 on the outboard side of the angles with the size and overallshape formed by the angles being such that the sub-assembly 36 formedthereby will be slidably received in the rearmost edge of the inboardsurfaces 38 of the panels 14, 16, and 18. The particular configurationshown is rectangular, however, any desired configuration may be achievedby appropriately shaping and assembling the angles 25, 29, and 32.

A pair of spaced parallel, opposed, intermediate angles 40 extendbetween and are attached to the angles 29 and 32. The angles 40 eachhave an L-shaped cross-section and extend parallel to the side angles 25in the same plane therewith. Each angle 40 includes a shell mountingflange 41 corresponding to flanges 26, 30, and 34 and an exposed panelmounting flange 42 corresponding to flanges 28, 31, and 35. The flanges'41 are so positioned that when the sub-assembly 36 is positioned insidethe shell 10, the flanges 41 will be in juxtaposition with the rearwardedges of the outboard surfaces 44 of the sub-panels 20.

A pair of spaced parallel intermediate cross-braces 45 extend betweenthe side angles 25 and are connected with the side angles 25 andintermediate angles 40. The crossbraces 45 are parallel to the angles 29and 32 and have an L-shaped cross-section. Each cross-brace 45 has ashell mounting flange 46 corresponding to the flanges 26, 30, 34, and41, and an exposed panel mounting flange 48 corresponding to the flanges2'8, 31, 35, and 4 2. The cross-braces 45 are so positioned that theflanges 46 lie in juxtaposition with the rearward edge of the top andbottom outboard surfaces 44 of the sub-panels 20 when the sub-assembly36 is in position within the shell 10.

The frame assembly 11 further includes a pair of spaced parallelhat-shaped support members 49 which are spaced forward of andsubstantially in alignment with the intermediate angles 40. Each supportmember 49 includes a U-shaped central portion 50 having a central web 51and aligned legs 52 integral therewith and extending from opposite edgesof the web 51. The extending edge of each of the legs 52 has integraltherewith an outwardly extending lip 54 parallel to the web 57. Themembers 49 are so positioned with respect to the sub-assembly 36 thatthe lips 54 lie in juxtaposition with the inside surface 55 of the frontpanel 12.

A plurality of truss braces 56 extend between and are attached to themembers 49 and intermediate angles 40 to properly position the members49 with respect to the sub-assembly 36. When the frame assembly 11 isattached to the panels 12, 14, 16, and 18, and the sub-panels 2'0, in amanner similar to that shown in FIG. 5, the Wall panel becomes a strongunit which is also light in weight.

The frame assembly shown in FIG. 4, has a construction simliar to theframe assembly 11 with side angles, a top angle 129, a bottom angle,intermediate angles cross braces 145, hat-shaped support members andtruss braces 156 corresponding respectively to the side angles 25, thetop angle 29, the bottom angle 32, the intermediate angles 40, thecross-braces 45, the hat-shaped support members 49, and the truss braces56 in FIG. 1. In addition the frame assembly of FIG. 4 also includes ahorizontally extending hat-shaped cross member 157 which has acrosssectional shape the same as the member 49 with a web 158, legs 159,and lips 160. The member 156 serves to reinforce the panel 12 and hasthe lips 160 lying in juxtaposition with the inside surface 55 of panel12.

The frame assembly in FIG. 5, has a construction similar to the frameassembly 11 with side angles 225, a top angle, a bottom angle,intermediate angles 240, crossbraces 245, hat-shaped support members249, and truss braces 256 corresponding respectively to the angles 25,29, 32, and 40, the cross-braces 54, the members 49, the truss braces56, in FIG. 1. In addition, auxiliary angles 295, having a cross-sectionlike angles 240 extending between the top and bottom angles (not shown)and in alignment with members 24 9. The braces 256 extend between theangles 295 and members 249 to form the truss system.

In all three embodiments of the frame assembly and fiberglass shell, astrip of insulation material 162, such as an adhesive tape or rubberstrip coated on both sides thereof with an adhesive is positionedbetween each lip of the hat-shaped members 49, 149, or 249, and thefiberglass front panel 12 as seen in FIG. 3. The insulation material 162serves the initial purpose of enabling the support members 49 to bepositioned until they have been fiberglassed in place and moreimportantly, serve to insulate the support members 49 from thefiberglass front panel 12 to prevent direct transfer to heat thereto.Such heat transfer, which could be caused either in the process ofwelding the frame assembly to a building structure or from weatherchanges, has heretofore been a great problem in causing discoloration ofthe fiberglass shell 10. Likewise, insulation material 30 is alsopositioned between all points where the frame assembly of FIGS. 1, 4 or5 contact the shell 10. For sake of simplicity, the insulating material162 is shown in FIGS. 3 and 4 only, however, it is understood that suchmaterial 162 would be used in the other embodiments shown.

It is to be further understood that, by using the adhesive strips ofmaterial 162 to hold the components of the frame assembly of FIGS. 1, 4or 5 in place, the assembly may be assembled right in the shell 10.While the components of the assembly are held in place by the strips ofmaterial 162, the shell mounting flanges of the side angles 25, 125, 225are fiberglassed in place with a sub-layer of fiberglass as indicated inFIG. 5, by the reference character S. Likewise, the shell mountingflanges of angles 29, 32, 40 and 45, or 129, 132, 140 and 145, or 229,232, 240, and 249, are fiberglassed in position by a sub-layer S. Thelips 54, 154, or 254 are fiberglassed in position by sublayer S also.The lips 160 as shown in FIG. 4, are likewise fiberglassed in positionby the layer 8. This creates a sturdy structure with the shell 10 firmlyattached to the frame assembly 11, 111 or 211. The panel is placed onthe building by attaching the frame assembly thereto.

The window openings 19 in the shell 10 may be formed for any shapewindow. Further, such openings 19 may be lain on the inside thereof asseen in FIG. 5, or may have a rib extending around the inside thereofadjacent the rearmost edge of the opening 19 as seen in FIG. 4. Anappropriate groove 171 may be formed in the rib 170 to receive theangles 145 and 140. A window unit WI may be placed int he opening 19 asseen in FIG. 4 or a window unit WII placed in the opening 19 as seen inFIG. 5.

It should also be noted that the exterior of the fiberglass shell may beeither sanded or sandblasted to provide a roughened surface whereby acoating -R such as an epoxy resin may be applied to the exterior of theshell 10 as seen in FIG. 4, for enabling any desired outside appearance,such for example, as concrete, cast stone, exposed aggregate, or thelike. Coating R may be mixed with a sand aggregate prior to beingapplied to shell 10.

It should now be apparent that the wall panel of the herein describedinvention is both inexpensive and easy to construct and may conform toany particular shape desired. It should also be apparent that while theinvention has been described with reference to particular shaped supportmembers, that it is not so limited and that any desired shape or numberof support members may be readily used.

A plurality of the wall panels are attached to a building structure todefine the exterior appearance thereof. The sealing flanges 22 overlapthe adjacent wall panels as seen in dashed lines in FIG. 5, and a jointcompound I, also seen in dashed lines in FIG. 5, is placed between thepanels to seal the same. The joint compound I serves as an expansionjoint between wall panels. Moreover, since the front panel 12 isconnected to the frame assembly 11, 111, or 211, at a minimum number ofpoints, each of the wall panels will act as an expansion joint as well.

The wall panel is usually constructed by first forming the shell 10. Theframe assembly of FIGS. 1, 4 or 5 may be first attached to the shellwith the strips of material 162 component by component and thenfastening the components together. On the other hand, the components maybe attached together and then placed in the shell 10 with the strips162. After the frame assembly is in place, the fiberglass sub-layers Sare formed to hold the frame assembly in place in the shell 10. Next theshell 10 is sanded or sandblasted on the exterior thereof and the resinR with the appropriate finish therein is applied. Finally, the windowunit WI or WII is installed and the wall panel is finished.

The inside of the completed panel may be filled with an insulatingmaterial or foam F as seen in FIGS. 4 and 5. The material F in FIG. 4 isthinner than that shown in FIG. 5.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings without departingfrom the scope of the invention otherwise than as specifically describedherein.

What is claimed as my invention is:

1. A wall panel for a building structure to define its exteriorappearance and configuration comprising a fibreglass outer shell, aframe assembly at least partly positioned within said shell, and atleast one fibreglass sublayer connecting said shell with said frameassembly; said fibreglass shell including a front panel, a pair ofopposed side panels integral with the edges of said front panel andextending rearwardly therefrom, a top panel integral with the top edgeof said front panel, extending rearwardly therefrom and joined with theupper ends of said side panels, and a bottom panel integral with thebottom edge of said front panel, extending rearwardly therefrom andjoined with the lower ends of said side panels; said frame assemblyincluding a pair of opposed side members, a top member joining said sidemembers at one end thereof, a bottom member joining said side members atthe opposite end thereof, at least one intermediate member joining saidtop and bottom members intermediate their ends, a support member spacedfrom and aligned with said intermediate member, and at least one trussmember connecting said support member with said intermediate member;said top, side and bottom members slidably received in juxtapositionwith the rearward inside surface of said side, top and bottom panels ofsaid shell, and said support member being positioned in juxtapositionwith the rear surface of said front panel; and said fibreglass sub-layerconnecting said side, top and bottom members with said side, top andbottom panels respectively and said support member with said frontpanel.

2. A wall panel as set forth in claim 1 further including insulationmeans positioned between said shell and said frame assembly at thepoints of contact therebetween for substantially reducing the heattransfer between said shell and said frame assembly.

3. A wall panel as set forth in claim 1 wherein the exterior surface ofsaid shell is coated with resinous finishing coating.

4. A wall panel for a building structure comprising a front panel; top,bottom and side panels extending from the rear of said front panel andintegrally united with the front panel and with each other to form acontinuous wall surrounding the rear face of said front panel, a secondset of top, bottom and side panels, parallel respectively to the firstmentioned top, bottom and side panels, integral width and extendingrearwardly from the rear face of the front panel to provide a windowopening, and a frame assembly comprising top, bottom and side membersjoined together to form a frame fitting slidably within the saidcontinuous wall, said frame. assembly including a pair of longitudinalmembers parallel to each other and to the side panels of the second setand so spaced as to slidably engage the said side panels of said secondset when the frame assembly is fitted within said continuous wall beingformed of fibreglass; and a fibreglass sub-layer connecting said firstmentioned side, top and bottom panels to said side, top and bottommembers, respectively, of said frame assembly.

5. The wall panel of claim 4 wherein said frame assembly furtherincludes a pair of spaced parallel members extending transversely of theframe and adapted to respectively engage the top and bottom panels ofsaid second set.

6. The wall panel of claim 5 wherein the panels of the second mentionedset are united to the adjacent members of the frame assembly by afibreglass layer.

7. A wall panel as set forth in claim 6 wherein insulation is positionedbetween the frame and the adjacent panel surfaces to reduce heattransfer.

8. A wall panel as set forth in claim 7, further comprising a supportmember, engaging the rear surface of said front panel, said supportmember being spaced from and parallel to one of said first mentionedlongitudinal members, and a truss connecting said support with said lastmentioned member.

References Cited UNITED STATES PATENTS 2,839,442 6/1958 Whitaker 161--683,213,570 10/ 1965 Abramson 52-309X 3,306,956 2/1967 Barnette 161-68X3,383,802 5/1968 Janssens 52-630X JOHN T. GOOLKASIAN, Primary ExaminerJ. C. GIL, Assistant Examiner "US. Cl. X.R.

